Assembly In Action: Robots Weld Parts in Small Batches

Crown Equipment Corp., of
Greencastle, IN, manufactures electric lift trucks for use in warehouses,
distribution centers and manufacturing facilities. Unlike many assemblers, the
company fabricates about 85 percent of the parts it uses. Parts are often made
in small quantities-sometimes as few as one at a time-to meet real-time demand
on the assembly line.

Historically, Crown Equipment welded the more than 1,500 miscellaneous parts it
requires manually in nine welding stations using the MIG process. The company
also employed manual welding to fabricate the four different frames it uses in
its lift trucks.

A few years ago, however, the company
implemented three stand-alone welding cells from welding equipment manufacturer
Lincoln Electric Co. Each cell employs a six-axis robot from Fanuc Robotics
America Inc. and a Lincoln Electric Power Wave 455M power source and Super Arc
L-56 MIG wire.

The result has been an improvement in both weld quality and cycle times.
According to Crown engineers, the cells are three to four times faster than
their manual counterparts. The average weld times have dropped from five or 10
minutes to two to three minutes. Welds are also more consistent and are overall
better in quality.

To facilitate the use of automation, Crown engineers created dozens of new
robotic welding fixtures, all based on a standardized 24-by-36-inch or 30-by
54-inch mounting plate.

In operation, as soon as a new fixture is installed into the welding cell, the
operator calls up a stored code for the part to be welded by entering a
three-digit code on the cell’s control panel. This automatically loads the
stored program into the robot’s teach pendent.

According to Crown, the robots are fast enough that they more than compensate
for the downtime associated with changeovers, even when producing single parts.
As evidence of their effectiveness, Crown cites the cells’ fast return on
investment. The company’s first cell, for example, paid for itself in about
four months.

“Lincoln Electric and Fanuc Robotics really
helped us realize this change, and it was their experience finding these kinds
of opportunities and making them work, along with the equipment design and
integration, that ultimately resulted in Crown choosing Lincoln Electric and
Fanuc,” says Crown senior vice president David Besser. “We have not had a
single equipment failure with any of these products. We are very pleased with
all the results.”

Events

Each year The ASSEMBLY Show provides assembly driven content, education and suppliers and the 2016 event will continue that trend. Suppliers, buyers and users will discover new assembly techniques, products and services once via ReBroadcast after The ASSEMBLY Show on November 8th. Attend remotely through Free Webinars and network with colleagues, download resources, socially integrate and more

Manufacturing relies on tools and aids, including jigs, fixtures, templates and gauges to maintain quality and production efficiency. With 3D printing technology, you can put more complex and custom jigs and fixtures on the production floor, in less time. In this webinar you’ll see how manufacturing companies are using 3D printed jigs and fixtures for increased productivity.